Stock material, protective packaging product and method

ABSTRACT

A protective packaging product comprises a paper tube and an interconnected string of air filled pillows positioned within the paper tube. The paper tube is preferably a Kraft paper tube, and the air filled pillows are preferably plastic air filled pillows. The paper tube and interconnected string of air filled pillows can include perforations facilitating the tearing off of a selected length of the protective packaging product. A method of providing a protective packaging product comprises providing an elongated plastic film tube; providing an elongated paper tube; positioning the plastic film tube within the paper tube; inflating the plastic film tube; and forming a series of transverse heat seals in the plastic film tube to thereby form an interconnected string of air filled pillows within a paper tube. The method can further comprise providing perforations in the plastic film tube and the paper tube facilitating the tearing off of a selected length of the protective packaging product, or severing the plastic film tube and paper tube to produce a selected length of the protective packaging product.

FIELD OF THE INVENTION

[0001] This invention relates generally to protective packaging products, and more specifically to an improved protective packaging product for use as bottom fill.

BACKGROUND OF THE INVENTION

[0002] In the process of shipping an item from one location to another, a protective packaging product is typically placed in the shipping carton or box, to fill any voids and/or to cushion the item during the shipping process. Examples of protective packaging products are foam “peanuts,” air filled plastic “pillows,” and paper sheet “converted” into crumpled paper pads or “dunnage.”

[0003] “Bottom fill” is the protective packaging product placed in the bottom of a box. Bottom fill presents unique challenges. For example, when crumpled paper pads are placed in the bottom of a box as bottom fill, a relatively heavy item placed thereatop tends to crush the paper pads. On the other hand, when air filled plastic pillows are placed in the bottom of a box as bottom fill, a relatively heavy item placed thereatop tends to burst the air pillows.

[0004] It is desirable to provide an improved bottom fill protective packaging product.

SUMMARY OF THE INVENTION

[0005] The present invention is a protective packaging product comprising a paper tube and an interconnected string of air filled pillows positioned within the paper tube. The paper tube is preferably a Kraft paper tube, and the air filled pillows are preferably plastic air filled pillows. The paper tube and interconnected string of air filled pillows can include perforations facilitating the tearing off of a selected length of the protective packaging product.

[0006] In another aspect, the method of providing a protective packaging product comprises providing an elongated plastic film tube; providing a pair of elongated paper sheets; sandwiching the plastic film tube between the paper sheets; adhering the confronting lateral edges of the pair of elongated paper sheets together; inflating the plastic film tube; and forming a series of transverse heat seals in the plastic film tube to thereby form an interconnected string of air filled pillows within a paper tube. The method can further comprise providing perforations in the plastic film tube and paper sheets facilitating the tearing off of a selected length of the protective packaging product, or severing the plastic film tube and paper sheets to produce a selected length of the protective packaging product.

[0007] In yet another aspect, a method of providing a protective packaging product comprises providing an elongated plastic film tube; providing an elongated paper tube; positioning the plastic film tube within the paper tube; inflating the plastic film tube; and forming a series of transverse heat seals in the plastic film tube to thereby form an interconnected string of air filled pillows within a paper tube. The method can further comprise providing perforations in the plastic film tube and the paper tube facilitating the tearing off of a selected length of the protective packaging product, or severing the plastic film tube and paper tube to produce a selected length of the protective packaging product.

[0008] In yet another aspect, a method of forming a stock material from which to make a protective packaging product comprises providing an elongated plastic film tube; providing a pair of elongated paper sheets; sandwiching the plastic film tube between the paper sheets; and adhering the confronting lateral edges of the pair of elongated paper sheets together. The method can further comprise providing perforations in the plastic film tube and paper sheets facilitating the tearing off of a selected length of the protective packaging product.

[0009] In yet another aspect, a method of forming a stock material from which to make a protective packaging product comprises providing an elongated plastic film tube; providing an elongated paper tube; and positioning the plastic film tube within the paper tube. The method can further comprise providing perforations in the plastic film tube and the paper tube facilitating the tearing off of a selected length of the protective packaging product.

[0010] By combining the paper tube with the interconnected string of air filled pillows a protective packaging product is produced which is able to function effectively as bottom fill for heavier items without bursting the air filled pillows.

[0011] These and other features and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a perspective view of a machine for producing the protective packaging product of the present invention;

[0013]FIG. 2 is a side view thereof;

[0014]FIG. 3 is a front view thereof;

[0015]FIG. 4 is a side view of one technique for forming the stock material for feeding into the machines of FIGS. 1-3 for forming the protective packaging product of the present invention; and

[0016]FIG. 5 is a top view of the stock material of FIG. 4 and/or a top view of the protective packaging product made from same.

DETAILED DESCRIPTION OF THE INVENTION

[0017] Referring first to FIG. 1, there is illustrated a machine 10 for producing the protective packaging product 12 of the present invention. Machine 10 can be, for example, an Airplus® machine commercially available from the Assignee of the present invention, heretofore used to make strings of interconnected air filled plastic pillows.

[0018] Referring now to FIGS. 1-3, machine 10 can include a machine frame 14, a stock supply roll 16, a separator 18, a pair of drive rollers 20, 20, a pair of transverse perforating/heat seal bars 22, 22 and an inflation needle 24 connected to a source of compressed air (not shown). As the stock material 26 (described in more detail below) is fed off of the roll 16 by drive rollers 20, 20, separator 18 separates the plies of the stock material. Inflation needle 24 periodically pierces one ply of the stock material 26 and inflates the stock material. Transverse perforating/heat seal bars 22, 22 periodically form a pair of transverse heat seals across the width of the stock material 26, sealing over the inflation holes formed in the material 26 by the needle 24, as well as a line of perforations across the width of the stock material 26 and between the pair of transverse heat seals, thereby forming the protective packaging product 12.

[0019] Referring now to FIGS. 4 and 5, a roll 16 of the stock material 26 according to the present invention is shown being manufactured. An elongated plastic film tube 30 is sandwiched between a pair of elongated paper sheets 32, 32. Plastic film tube 30 is preferably primarily low density polyethylene about 0.0021 inches thick. Paper sheets 32 are preferably about 30-60 pounds basis weight. The confronting lateral edges of the pair of elongated paper sheets 32, 32 are adhered together as with glue 34 to thereby form a paper tube. Stock material 26 can then be rolled into stock supply roll 16 for feeding into machine 10 to produce the protective packaging product 12 of the present invention.

[0020] Alternatively, the paper tube could be formed from a single sheet of elongated paper whose lateral edges are overlapped slightly and adhered together. In that case, the elongated plastic film tube and the elongated paper tube could be formed in separate steps. The plastic film tube could then be positioned within the paper tube to form the stock material 26, which could then be rolled into stock supply roll 16 for feeding into the machine 10.

[0021] Referring now to FIG. 5, and as discussed above, machine 10 includes perforating/heat sealing bars 20, 20. These bars 20, 20 simultaneously form a pair of transverse heat seals 28, 28 in the plastic film tube 30, a line of perforations 36 in the plastic film tube 30 and a line of perforations 38 in the paper tube formed from the glued together paper sheets 32, 32. The perforations facilitate the tearing off of a selected length of the protective packaging material 12. Rather than the machine 10 including a perforating mechanism to perforate the material 26, plastic film tube 30 and/or paper tube 32 could be pre-provided with the perforations 36, 38, respectively. Alternatively, machine 10 can include a severing device (not shown) for severing a selected length of the protective packaging product 12.

[0022] Those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the present invention which will result in an improved packaging product and method, yet all of which will fall within the spirit and scope of the present invention as defined in the following claims. For example, while separate plastic film and paper tubes have been shown and described, the invention could as well be practiced with a composite plastic film and paper tube formed by a process wherein an elongated plastic film sheet is first laminated to an elongated paper sheet, and then the laminated plastic and paper material is formed into an elongated tube, either by adhesively securing overlapping lateral edges of the laminated plastic and paper material or by heat sealing overlapping lateral edges of the laminated plastic and paper material. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents. 

What is claimed is:
 1. A protective packaging product comprising: a paper tube; and an interconnected string of air-filled pillows positioned within said paper tube.
 2. The protective packaging product of claim 1 wherein said paper tube is a Kraft paper tube.
 3. The protective packaging product of claim 1 wherein said air filled pillows are plastic air filled pillows.
 4. The protective packaging product of claim 1 wherein said paper tube and interconnected string of air filled pillows include perforations facilitating the tearing off of a selected length of said protective packaging product.
 5. A method of providing a protective packaging product comprising: providing an elongated plastic film tube; providing a pair of elongated paper sheets; sandwiching the plastic film tube between the paper sheets; adhering the confronting lateral edges of the pair of elongated paper sheets together; inflating the plastic film tube; and forming a series of transverse heat seals in the plastic film tube to thereby form an interconnected string of air filled pillows within a paper tube.
 6. The method of claim 5 further comprising: providing perforations in the plastic film tube and paper sheets facilitating the tearing off of a selected length of the protective packaging product.
 7. The method of claim 6 further comprising: severing the plastic film tube and paper sheets to produce a selected length of the protective packaging product.
 8. A method of providing a protective packaging product comprising: providing an elongated plastic film tube; providing an elongated paper tube; positioning the plastic film tube within the paper tube; inflating the plastic film tube; and forming a series of transverse heat seals in the plastic film tube to thereby form an interconnected string of air filled pillows within a paper tube.
 9. The method of claim 8 further comprising: providing perforations in the plastic film tube and paper tube facilitating the tearing off of a selected length of the protective packaging product.
 10. The method of claim 8 further comprising: severing the plastic film tube and paper tube to produce a selected length of the protective packaging product.
 11. A method of forming a stock material from which to make a protective packaging product comprising: providing an elongated plastic film tube; providing a pair of elongated paper sheets; sandwiching the plastic film tube between the paper sheets; and adhering the confronting lateral edges of the pair of elongated paper sheets together.
 12. The method of claim 11 further comprising: providing perforations in the plastic film tube and paper tube facilitating the tearing off of a selected length of the protective packaging product.
 13. A method of forming a stock material from which to make a protective packaging product comprising: providing an elongated plastic film tube; providing an elongated paper tube; and positioning the plastic film tube within the paper tube.
 14. The method of claim 13 further comprising: providing perforations in the plastic film tube and paper tube facilitating the tearing off of a selected length of the protective packaging product. 